Usage:
Start By:
a. remove front tires and rims
1. Remove brake line (2) from brake caliper (1) and the manifold block. Plug the opening to prevent brake oil loss or dirt entry.
2. The weight of the caliper is 47 kg (103 lb). Fasten tooling (A) to the brake caliper, and attach a hoist as shown. Remove six bolts (3), and remove the caliper.
NOTE: The following steps are for installation of the front brake caliper.
3. Fasten tooling (A) and a hoist to the caliper, and put it in position on the spindle assembly. Install six bolts (3). Tighten the bolts to a torque of 750 ± 80 N·m (550 ± 60 lb ft).
4. Loosen bolts (4) that hold pins (6) in place. Measure the distance between pins (6) and the brake disc with feeler gauge (5). The distance must be 1.5 ± 0.5 mm (.06 ± .02 in). Move the pins in or out to obtain the correct clearance. Tighten bolts (4) to a torque of 46 ± 3 N·m (34 ± 2 lb ft).
5. Install brake line (2) on the brake caliper and the manifold block.
6. Remove (bleed) the air from the brake system. See Testing And Adjusting, Form SENR5645, for the proper procedure.
End By:
a. install front tires and rims
Disassemble Front Brake Calipers
Start By:
a. remove front brake calipers
1. Loosen bolts (3) from the brake caliper.
2. Loosen two pins (1), and remove brake lining (2) from the brake caliper.
3. Remove bolts (4) to remove cover (5) from the brake caliper.
4. Remove plugs (6) and the seals from the brake caliper.
5. Use a soft hammer, and remove pistons (7) from the brake caliper.
6. Remove boots (8) and the seals.
7. Install tool group (A) on the brake caliper as shown. Remove the outside pistons with tool group (A).
8. Remove outside boots (9) and the seals.
Assemble Front Brake Calipers
1. Install the seals in the bores of the brake caliper.
2. Use tool (B) to install boots (1) in the bores of the brake caliper.
3. Install pistons (2) with tool group (A).
4. Install the seals in the bores of the brake caliper.
5. Use tool (B) to install boots (3) in the bores of the brake caliper.
6. Use tooling (C) to install the pistons.
7. Install seals (4) and plugs (5) in the bores of the brake caliper.
8. Install cover (6) and the bolts that hold it. Tighten the bolts to a torque of 95 ± 7 N·m (70 ± 5 lb ft).
9. Install brake linings (7). Tighten pins (8) and bolts (9).
End By:
a. install front brake calipers